Package material and package container formed with said material

ABSTRACT

Package material comprises one or more layers of plastic laminate, a first side, a second side and a penetration area ( 40 ). A weakening line ( 30 ) extends from the penetration area ( 40 ) and provides an opening area ( 12 ) in the package material. The package material comprises a plastic opening device ( 2 ), with a first and second portion ( 4 ) attached to the first and second side, respectively and a material bridge ( 45 ) penetrating through the penetration area ( 40 ). The second portion covers at least partly the penetration area and comprises a guiding portion ( 35, 36 ) extending from the penetration area ( 40 ) adjacent to the at least one weakening line ( 30 ) as to facilitate rupturing substantially along the at least one weakening line.

This is a National Phase of PCT Application No. PCT/EP2015/078103, filedNov. 30, 2015, which claims the benefit of Swedish Application No1451627-2 filed Dec. 22, 2014, which is incorporated herein byreference.

The present invention relates to a package material and to a packagecontainer comprising such material.

BACKGROUND OF THE INVENTION

Package containers of the single use disposable type for food productsare often produced from a packaging material. Such packaging materialmay include paperboard or carton, but may also just contain differentplastic layer or metalized film layers. Consequently different kind offood products, like liquid, semi-liquid or solid food products can bestored in such containers.

One example is related to a simple bag, which can contain severalplastic layer sealed together to form a bag like shape in order to storefor example potato chips, candy's or other solid food products. Someother containers are suitable for aseptic packaging of liquid foods suchas milk, fruit juices, etc are marketed and sold for long term ambientstorage. The packaging material in such package container is typically alaminate comprising a bulk layer of paper or paperboard, outer,liquid-tight layers of thermoplastics, a gas barrier layer, mostcommonly an aluminum foil and finally one or more inside layers composedof one or several part layers, comprising heat-sealable adhesivepolymers and/or heat-sealable polyolefins.

Package containers are normally produced and filled on fully automaticpackaging machines. In one example, a continuous tube is formed from theweb-fed packaging material (said material can include carton basedmaterial, but pure plastic laminate may also be suitable); the web ofpackaging material is sterilized in the packaging machine, and thesterilized web of packaging material is maintained in a closed, sterileenvironment in the subsequent step. The web is folded and sealedlongitudinally to form a vertical tube. The tube is filled with thesterilized or sterile-processed food product, and is sealed andsubsequently cut along equally spaced cross sections to form pillowpacks, which are then folded mechanically to form respective finished,e.g. substantially parallelepiped-shaped, package containers.

Commonly, the package container have an opening device in order tofacilitate consumer opening, many different types of opening devicesincluding pull-tabs or molded opening devices, as for example discussedin WO03/095199 25 and WO/2009/000927.

However, the latter type of package is a high-volume (in terms ofpackages per time unit) and low-cost package (due to the properties ofthe packaging material), and complex openings might hamper theproduction speed and be detrimental for the cost of the package. On theother hand, the consumer requests an easy and appealing opening withgood pourability.

For this reason there is a need for an opening device having a highefficiency in regard of the amount of material used and meeting theconsumers' requests.

SUMMARY OF THE INVENTION

For the purpose of the invention, the term “package material blank” or“blank” shall include an individual sheet or a blank in a packagematerial web. Such package material web may comprise one or more“package material blanks” arranged after each other in a continuous web,some of those blanks in different processing stages, i.e. on one blankin such web may comprise an opening device, while other blanks on theweb might still be un-processed.

For the purpose of the invention, the terms “container, package” and“package” or “packaging container” refer to the same structure. Inaddition, the terms material, material laminate structure or packagingmaterial refers to the package material blank. The term “cellulosicmaterial” may comprise one or more layers of paper, cardboard or anyother cellulosic fiber based material.

In an embodiment, a package material comprises a multilayer materialstructure with one or more layers of plastic laminate. The multilayermaterial has a dedicated penetration area. On said area plastic materialpenetrates through the multilayer structure to be attached to one of thesurfaces of the multilayer structure as to form an opening on thepackage material. The package also comprises one or more weakeninglines, for example (but not limited to perforation or compression lines)

In an embodiment said one or more weakening lines extend from thepenetration area to provide an opening in the multilayer materialstructure when being ruptured. In another embodiment, a weakening linecircumferences the penetration area.

In accordance with the present invention, a plastic opening device isprovided on the multilayer structure, comprising a first and secondportion, at least the second portion being attached to the multilayerstructure. A material bridge penetrates through the structure andconnects the first and second portion of the opening device. The secondportion now at least partly covers the penetration area and comprises aguiding portion. Said guiding portion extends from the penetration areaadjacent to the at least one weakening line as to facilitate rupturingsubstantially along the at least one weakening line.

In accordance with the present invention, a more precise opening isachieved by guiding the rupture of the multilayer structure along saidone or more weakening lines. The guiding portion supports the rupturingalong those lines. As the applicant found out, the weakening line alonedoes not guarantee under all circumstances a rupture along the weakeningline. In fact, the material structure is often ripped apart differently,resulting not only in reduced visual appearance, but also in pouringproblems. The guiding portion facilitates the rupture process and maycompensate different opening techniques used by the consumer whenopening a package made from said material.

In an embodiment, the guiding portion comprises at least one leg sectionhaving an edge following the curve of the one or more weakening line. Itmay be useful, if the leg section or parts of the guiding portion ingeneral is arranged on the area of the multilayer structure, which formsthe opening space. In an embodiment, the guiding portion comprises twoleg sections on both sides of the weakening line(s). Such embodimentimproves the guiding characteristics during opening. The two legs oneach side of the weakening line can be closed at their respective end,thus enclosing the end of the weakening lines. Such embodiment maysupport the opening process by the consumer, such that the rupture ofthe multilayer structure is prevented from continuing beyond theweakening lines.

To further improve guidance and easy opening, the second portion maycomprise a recessed material line extending adjacent to the one or moreweakening lines towards the penetration area. It may encircle thepenetration area, but actually not cross or touch it. The recessedmaterial line will be an advantage, if the second portion extends overthe portions of the weakening line(s). In such embodiment the recessedmaterial line may follow the curve of the underlying weakening line.Particularly it may be continuous and follow the shape. In some area therecessed material line may avoid the penetration area by moving aroundsaid penetration area. The recessed line can be rather deep, for exampleup to 30% to 90% of the second's portion thickness, or between 50% to80% of the thickness.

To reduce bouncing of the rupture line during the opening, the distancebetween the guiding portion and the weakening line is rather small andin the range of a few 100 μm to about 1.5 mm.

In an embodiment, the material of the second portion crosses theweakening line and particularly the perforation at a spot, at which themultilayer structure is not weakened or perforated. Otherwise someleakage problems may occur as the plastic material of the second portionmay rupture the perforation at that spot during molding of the opening.

Another aspect is related to the multilayer structure. In an embodiment,the multilayer structure in the opening area provided by weakeningline(s) comprises a cellulosic layer, said layer being absent in thepenetration area. Thus the material forming the opening device can beinjected through the penetration area more easily and defect issuescaused by ripping through cellulosic material are prevented.Alternatively, the penetration area may comprise a reduced thicknesscompared to the surrounding areas and particular the multilayerstructure in the opening area.

The penetration area may comprise different characteristics. Forexample, it can be larger than an area covered by the material bridge.It may have different shapes, i.e. circular, elliptic and rectangular orany other shape that fits the material bridge and the purpose ofpenetrating through the area.

DESCRIPTION OF THE DRAWINGS

In the following, the invention is explained in greater detail supportedby several embodiments and the accompanying drawings, in which

FIG. 1 illustrates a perspective view of a first embodiment of thepresent invention;

FIG. 2 shows the side view of the first embodiment according to FIG. 1;

FIG. 3 shows a bottom view of the embodiment according to FIG. 1;

FIG. 4 illustrates a perspective view of a second embodiment accordingto the present invention;

FIG. 5 shows the bottom view of the second embodiment;

FIG. 6A illustrates a top view of a third embodiment according to thepresent invention;

FIG. 6B shows the bottom view of the embodiment according to FIG. 6A;

FIG. 7A shows a fourth embodiment;

FIG. 7B illustrates the bottom view of the fourth embodiment;

FIG. 8 illustrates a perspective view of a fifth embodiment, without thepackage material, similar to the second embodiment of the presentinvention;

FIG. 9 shows a perspective view of a sixth embodiment in accordance withthe present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 illustrates a perspective view of a packaging material 1 inaccordance with the present invention. An opening device 2 is attachedto a multilayer material structure 10 in a certain area to facilitate anopening as it will be explained later.

The multilayer structure 10 comprises one or more layer of plasticmaterial. The plastic material layers can be of different material andmay have different thickness, opaque or transparent to achieve certaineffects, i.e. acting as an oxygen barrier, a light barrier and the like.Multilayer structure 10 in this embodiment also comprises a carton layerbetween the plastic material layers. Such carton layer acts as a lightbarrier and also provides certain stiffness for the package material anda package made from such material. Multilayer structures of this typecan be found for example in European patent application EP13199808 orpublication EP592920, the content of which related to the packagematerial composition is herewith incorporated by reference.

The opening device 2 comprises a first or grip portion 20 for rupturingmultilayer structure 10 to create an opening. The grip portion 20 isconnected to a bridge material portion 45, which penetrates themultilayer structure in a penetration area 40. Said penetration area 40is different from the surrounding area of the multilayer structure 10.For example penetration area 40 comprises a lower thickness than thesurrounding areas due to the lack of one or more layers of themultilayer structure. In other words, the thickness of penetration area40 is reduced by removing one or more layer of the multilayer structurein said area. Alternatively, the thickness in penetration area 40 can bereduced by compression or other techniques. The penetration area 40 isof rectangular shape and slightly larger than the bridge'scross-section. This allows compensating for small positioning errorsduring the injection molding process forming the opening device 20.

The opening device 2 also comprises a second portion attached to thelower surface of the multilayer structure, which will be explained withreference to FIGS. 2 and 3. To facilitate the creation or forming of theopening, the multilayer structure comprises a weakening line 30,implemented in this embodiment as a perforation. Alternatively theweakening line can be formed as a compression line or by other means. Itacts as a guidance at which—ideally—the material of the multilayerstructure is ruptured, when the grip portion 20 is pulled to create theopening. The perforation 30 extends directly adjacent from thepenetration area 40 in two s-curved shaped manners. The distance betweenthe two s-curved perforation lines 30 is first increasing to a maximumdistance at area S and then slowly decreasing towards their respectiveends. The area 12 of the multilayer structure enclosed or partlyenclosed by the two weakening lines 30 forms the opening part of thedevice. In other words, when the opening device is pulled, the area 12is ruptured apart from the remaining multilayer structure creating theopening.

FIG. 2 and FIG. 3 show the cross-view and bottom view of the openingdevice 2 and its attachment on the surface of the multilayer materialstructure. The opening device is made by injection molding, wherein twomold halves are placed over each other enclosing the penetration area40. In the illustrated embodiment, plastic material is injected topenetrate though the whole penetration area and filling the areacompletely as seen in the cross-section. Said material forms bridge 45connecting the first or grip portion 20 of the opening device to thesecond portion 4. Second portion 4 comprises an extension 43 and anopening support 46. Opening support 46 extends from the material bridgeportion 45 onto the surface of the multilayer layer structure being partof the opening area 12. It comprises a centrally arranged pointed androunded end portion.

Extension 34 is arranged opposite the opening support 46 and covers aportion of the multilayer structure outside area 12. In this regard area12 is defined by the perforation line and its virtual extensionconnecting ends of the perforation together. Extension 43 and openingsupport 46 are separated by a material recess 42. Said recess comprisesa depth, which is about 70% to 90% of the second portion's thickness.The remaining material thickness in recess 42 may be in the range of afew 10 μm. Recess 42 extends from one edge of second portion 4 in acircular manner to the other edge of second portion. One can say thatrecess 42 is an extension of the weakening line 30 and “connects” bothperforation lines. Recess line 30 facilitates the opening and reducesthe opening force which at the same time acts as an initial rupturingpoint, when the grip portion is pulled. When recess line 42 is beingruptured in the initial step of the opening procedure, the rupturecontinues along the recess first and then extends to the perforationlines 30.

As can be seen from FIG. 2, the bridge portion 45 and particular theconnection to the first or grip portion 20 is arranged next to therecess 42 closer to area 12 and over opening support 46.

Second portion 4 also comprises two leg sections 36 and 35,respectively. Leg section 36 extends from the extension portion 46 andfollows the weakening lines 30 substantially parallel approximatelyshortly before the s-curved shaped perforation line switches itsdirection in the shape. Accordingly, a second leg section 35 (moreprecisely a second pair of leg section) extends from support section 46substantially parallel to the perforation line 30 to about the same endpoint. The leg section 35 is therefore arranged on area 12. The distancebetween the perforation line 30 and the respective leg sections 35 and36 is a few 100 μm. In this example, it is about the thickness of therespective legs. To improve the guiding of the leg sections it is oftensmaller than the thickness of the leg sections, and in the range of 100μm to 400 μm.

FIG. 4 illustrates a second embodiment of the present invention. In thisembodiment, the penetration area 40 is rather small and approximately inthe size of the material bridge 45 penetrating the multilayer materialstructure in penetration area 40. The grip portion 20 comprises the sameshape as in the first embodiment. As illustrated the weakening orperforation line 30 extends from one end on the multilayer structurearound the bridge 45 and the penetration area 40 to the other end.Perforation line 30 is spaced apart from penetration area 40 by distanceD. As a result, area 12 is encircling the penetration area 40. This isdifferent from the first embodiment according to FIG. 1, wherein area 12abuts only a part of penetration area 40. Due to the shape ofperforation line 30, said distance is smallest at the edges ofpenetration area 40.

A bottom view of the second embodiment is illustrated in FIG. 5. Openingsection 46 of the second portion comprises a curved shape divided into acircular and a subsequently attached linear shape. A small recess in themiddle reduces material consumption of the support section. The legsection 35 extends from the second portion substantially parallel to theperforation line 30 all the way to its end 33, at which it encircles theperforation line to turn into the outer leg section 36. In other words,the leg sections 35 and 36 encircle the perforation line 30 on bothsides completely. Their distance to perforation line 30 is similar tothe one described in the first embodiment.

FIGS. 6A and 6B now illustrate the top and bottom view of a similarembodiment to the one in FIG. 1. The grip portion 20 turns into thebridge portion 45 at its upper end, wherein bridge portion 45 comprisesa reinforcement bar 48. The reinforcement bar 48 enhances the stabilitywhen the grip portion is pulled, because bridge portion 45 is arrangedover the recess line 42 in the second portion 4 as seen on FIG. 6B.Recess line 42, as illustrated in FIG. 3B is adjacent to the perforationline 30 and extends in a curved shaped manner across the second portion4, thereby separating said portion into section 43 and opening support46. Extension 43 is shaped with a smaller radius than recess lines 42providing stability to facilitate the initiation of the rupture onrecess line 42.

As one can see, the perforation line 30 is covered in area 41A withmaterial of second portion 4 at a perforated part of the multilayerstructure. In addition, second portion 4 extends over circular shapedpenetration area 40. Consequently, a part of second portion 4 includingthe recess line 42 extends over and covers the perforation line 30 inarea 41A of FIGS. 6A and 6B. The perforation line itself extends belowthe plastic material of second portion 4 till the penetration area andparticularly to a spot in the middle of the penetration area, i.e. wherethe diameter of the penetration area is largest.

As recess line 42 and perforation line 30 partly overlap as shown inFIGS. 6A and 6B, the perforation line will easily be ruptured after theinitial rupture of recess line 42. The required force for the initialrupture is generally higher than the force needed to extend the rupture,however it is already reduced due to the recess line. The leg sections35 and 36 on both sides of the perforation ensure a rupture along theperforation, because the required force to rupture the multilayerstructure across the leg sections 35, 36 is higher than along theperforation line 30. Leg sections 36 end at a portion, where thedirections of both perforation lines are facing each other.

In the embodiment according to FIGS. 6A and 4B the outer edges of secondportion 4 including the leg sections comprise a higher thickness thanthe area within the border strip. This will further strengthen thematerial to guide the rupture and reduce disfigured rupture line intothe plastic material of second portion 2.

FIGS. 7A and 7B illustrate an alternative opening device attached on amultilayer structure in accordance with the present invention. In theembodiment, penetration area 40 is displaced with respect to a virtualextension 30A of perforation line 30. While in the previous embodiment,the perforation line extend from a spot on the penetration area close toa central horizontal virtual line though the centre of area 40, theperforation line 30 in FIGS. 7A and 7B “hit” the penetration area at aspot beneath the central horizontal virtual line. In other words thedistance between the two end points of the perforation line 30 adjacentto the penetration area is less than the diameter of said area (incontrast to the previous embodiment, where it is about the same).

The material bridge 45 through penetration area 40 is displaced and nowlocated outside area 12, given that area 12 is defined by perforationline 30 and any virtual extension 30A connecting end of perforation line30 together. To facilitate an easy opening, preferably on a recess,recess 42 a in the second portion 4 is shaped in such way to follow thematerial bridge. Recess 42A comprises two small sections extending fromthe respective edge areas 41B until they overlap the penetration area40, at which they bend upwards. Recess line 42A then encircles bridgeportion 45. A middle portion of recess line 42A is substantiallystraight and parallel to the material bridge width. The structureaccording to this embodiment reduces the initial opening force andresults in a more evenly distributed force during the opening process.

FIG. 8 illustrates another embodiment as seen from a perspective view,but without the multilayer material structure. Consequently, one can seethe first or grip portion 20 and the second portion 4. Grip portion 20comprises on its upper surface a periodic ripple structure to enhancethe gripping. It ends into the bridge material portion 45 penetratingthough the multilayer structure, of which only a small portion 70 of thepenetration area is illustrated. Said portion is the results of theinjection molding process, in which material is injected from the lowerside (bottom side of multilayer structure). The pressure of the injectedmaterial is high enough to penetrate the reduced multilayer structure inthe penetration area forming grip portion 20 and causing some material70 of multilayer structure to bend upwards. The material also flows intoleg portions 35 and 36.

FIG. 9 illustrates another embodiment, with shortened single legportion. The dotted line in FIG. 9 represents the perforation orweakening line 30 in the multilayer material structure (not shown in theembodiment. Leg portion 36C is extends from opening support 36 in arounded drop shaped manner. The end attached to the opening supportfirst decreases in width and follows substantially parallel theperforation line 30. Then it increases to an asymmetric droplet shapewith a lower curvature on side adjacent to the perforation line 30.Consequently, opening portion 46 and leg portion 46C follow theperforation line in a mushroom like shape.

Features of the different embodiment illustrates herein can be combinedin every way without deviating from the principle of guiding therupturing during the opening process with the help of a leg portionattached on one side of the package. In the embodiments shown, the legportion is attached to the lower side of the multilayer structure,opposite the grip portion. However, the leg portion can also beimplemented on the same side as the grip portion without deviating fromthe disclosed principle and within the scope of the claimed subjectmatter. In other words, the second portion can comprise the grip portionand the leg portions, while it is connected via the material bridge tothe first portion, said first portion formed on the “inside” of thepackage.

The invention claimed is:
 1. A package material for a packagingcontainer, the package material comprising: a material structure formedof one or more layers of plastic laminate, the material structurehaving: a first side; a second side opposite the first side; apenetration area configured to provide an opening in the packagingcontainer when the material structure is ruptured; and at least oneweakening line extending from the penetration area and configured tocreate the opening in the packaging container when the materialstructure is ruptured; and an opening device for opening the packagingmaterial and including: a first portion attached to the first side andconfigured to rupture the material structure to create the opening inthe packaging container; a second portion attached to the second sideand configured to facilitate rupturing the material structure to createthe opening in the packaging container; and a bridge penetrating throughthe penetration area and connecting the first portion to the secondportion, wherein the second portion at least partially covers thepenetration area and includes a guiding portion extending from thepenetration area adjacent to the at least one weakening line andconfigured to facilitate rupturing substantially along the at least oneweakening line.
 2. The package material according to claim 1, whereinthe guiding portion includes at least one leg section having an edgearranged at least partially substantially parallel to the at least oneweakening line.
 3. The package material according to claim 1, whereinthe at least one weakening line includes first and second weakeninglines, each weakening line extending from the penetration area to createan area on the material structure in between the area forming theopening.
 4. The package material according to claim 3, wherein thesecond portion covers at least a portion of the area forming theopening.
 5. The package material according to claim 3, wherein the firstand second weakening lines are s-curved shapes, wherein a distancebetween the first and second weakening lines increases in a firstsection and decreases in a second section, and wherein the secondportion covers at least a portion of the first section.
 6. The packagematerial according to claim 2, wherein the at least one leg section isarranged at a side of the at least one weakening line on the materialstructure, wherein the side of the at least one weakening line forms theopening when ruptured.
 7. The package material according to claim 2,wherein a distance from the at least one leg section to the at least oneweakening line is in a range of 50 to 1500 μm.
 8. The package materialaccording to claim 1, wherein the second portion includes a recessedmaterial line extending from a location of the second portion adjacentto the at least one weakening line towards an area overlapping thepenetration area.
 9. The package material according to claim 8, whereinthe recessed material line extends continuously from each location ofthe second portion adjacent to the at least one weakening line.
 10. Thepackage material according to claim 8, wherein the recessed materialline in the second portion is at least partially arranged over a sectionof the at least one weakening line covered by the second portion. 11.The package material according to claim 2, wherein a length of the atleast one leg section is smaller than a length of the at least oneweakening line.
 12. The package material according to claim 1, whereinthe at least one weakening line includes a perforation havingalternating perforated portions and bridge portions, wherein the secondportion ends on a bridge portion of the perforation.
 13. The packagematerial according to claim 1, wherein the material structure in thearea provided by the at least one weakening line comprises a cellulosiclayer, wherein cellulosic layer is absent in the penetration area. 14.The package material according to claim 1, wherein the penetration areaincludes a smaller vertical dimension than an area of the materialstructure surrounding the penetration area.
 15. The package materialaccording to claim 1, wherein the penetration area includes at least oneof: an area larger than an area covered by the bridge; a substantialcircular shape; a substantial rectangular shape; or the materialstructure in the penetration area having at least one layer less thanthe material structure of the surrounding area.
 16. A package containerhaving the package material according to claim 1, wherein: the packagematerial includes side edge portions; the package material is shaped toform the package container and sealed along the side edge portions, anda first seal is arranged substantially opposite the opening device andat least a second seal is arranged substantially perpendicular to theopening device.
 17. The package material according to claim 7, whereinthe distance from the at least one leg section to the at least oneweakening line is in a range of 500 to 1500 μm.
 18. The package materialaccording to claim 2, wherein the at least one weakening line extendsbeyond the guiding portion.
 19. A package material for a packagingcontainer, the packaging material comprising: a multilayer materialstructure having: a penetration area configured to provide an opening inthe packaging container when the material structure is ruptured; and atleast one weakening line extending from the penetration area andconfigured to create the opening in the packaging container when thematerial structure is ruptured; and an opening device for opening thepackaging material and having: a first portion attached to a first sideof the material structure and configured to rupture the materialstructure to create the opening in the packaging container; a secondportion attached to a second side of the material structure andconfigured to facilitate rupturing the material structure to create theopening in the packaging container; and a bridge connecting the firstportion to the second portion, wherein the second portion includes aguiding portion extending from the penetration area adjacent to the atleast one weakening line and configured to facilitate rupturingsubstantially along the at least one weakening line.
 20. The packagematerial according to claim 19, wherein the guiding portion includes atleast one leg section having an edge arranged at least partiallysubstantially parallel to the at least one weakening line.